Dehydrator system and methods of using the same

ABSTRACT

Provided herein are solids removal systems for dehydrator systems comprising a large rotating paddle, a small rotating paddle, and a drive shaft. The dehydrator system also includes a core dehydrator and a mixing unit. The core dehydrator comprises a plurality of small deflector plaques in fluidic communication with a plurality of large deflector plaques. The mixing unit includes a rapid mixing manifold in fluidic communication with a plurality of vertical flocculators and the core dehydrator. The large rotating paddle and the small rotating paddle of the solids removal system are connected to the drive shaft and configured to remove solids from the core dehydrator.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 15/275,064, which is a continuation-in part of InternationalApplication No. PCT/EC2015/000001, filed Mar. 26, 2015, which claims thebenefit of Ecuador Application No. IEPI-2015-10430 filed Mar. 18, 2015.The foregoing applications are incorporated herein by reference.

BACKGROUND OF THE INVENTION

Drilling fluids with high concentrations of salt and low densities areprocessed with equipment that allows for conservation of resources asthe water used in perforation wells located in arid regions can berecycled. However, there is a need to process high density drillingfluids (mud) and waste in different regions and provide clean wastewater without causing substantial pollution to the environment.

SUMMARY OF THE INVENTION

Dehydrator systems comprising a core dehydrator and a mixing unit aredescribed herein and methods of using the same. As shown in the figures,the core dehydrator comprises a turbulent flow mixing compartment, aturbulent flow transition zone, a clarifying sediment chamber, aplurality of small baffles, a plurality of large deflector plaques and aflocculation pipe. In the turbulent flow transition zone, fluid flowtransitions from turbulent flow to laminar flow. The mixing unitcomprises a plurality of vertical flocculators. The mixing unit furthercomprises a rapid mixing manifold. The rapid mixing manifold containsdrilling fluids and flocculant polymers.

The mixing unit can further comprise a water collector tank, a pluralityof stir tanks for dissolving polymer, a double paddle axial flow swirlgenerator and a stir tank for sludge conditioning. Each stir tank canhave one or more agitators. The mixing unit can further comprise a mudconditioning tank and a plurality of centrifugal pumps. In an aspect,the mixing unit comprises three flocculators.

As described herein and shown in the figures, the dehydrator system mayalso include a gearbox, a drawer storage gearbox, a connector shaft influid communication with an agitator, a bocin, a plurality of inclinedpalettes for axial flow, a plurality of radial vanes or palettes, a dragsolid transition zone, a circular cone, a circular cylinder, a pluralityof solid discharge pipes, one or more positive displacement pumps, oneor more water well transporters, a distributor water channel, a waterdischarge valve to recirculate and improve water quality, a waterdischarge valve for evacuating drilling system, one or more suctionpipes, a water distribution manifold, a plurality of solid removal jets,and solids discharge pipe in fluid communication with the positivedisplacement pump. The dehydrator system can further include a skid, aplurality of telescopic columns, and a plurality of ears fortransporting the system.

Also provided herein are dehydrator systems comprising a solids removalsystem, a mixing unit and a core dehydrator. The mixing unit comprises arapid mixing manifold positioned and a plurality of flocculatorchambers. In an aspect, the mixing unit also comprises a plurality ofstir tanks. In an aspect, the mixing unit further comprises a mudconditioning tank.

In the dehydrator system, the core dehydrator comprises a clarifyingsediment chamber having plurality of small deflector plaques, aplurality of large deflector plaques and a drag solid transition zone.The rapid mixing manifold is in fluidic communication with the pluralityof flocculator chambers. The clarifying sediment chamber is in fluidiccommunication with the drag solid transition zone. The drag solidtransition zone is in fluidic communication with the plurality offlocculator chambers.

In the dehydrator system, the solids removal system is fluidiccommunication with the drag solid transition zone of the coredehydrator. The solids removal system comprises a large rotating paddle,a small rotating paddle, and a drive shaft. The draft shaft is connectedto the large rotating paddle and the small rotating paddle andconfigured to rotate the large rotating paddle and the small rotatingpaddle for removing solids from the dehydrator system. In an aspect, thelarge rotating paddle and the small rotating paddle are configured tomove solids out of the core dehydrator. In an aspect, the coredehydrator comprises a large cylindrical section and a small cylindricalsection in fluidic communication with the large cylindrical section. Thelarge rotating paddle is positioned with the large cylindrical section.The small rotating paddle is positioned within the small cylindricalsection. In an aspect, a solids pump in fluidic communication with thecore dehydrator.

Also provided herein are methods of removing solids from drilling fluidscomprising the steps of: (a) providing drilling fluids to a dehydratorsystem; (b) mixing drilling fluids with polymer solution in the mixingunit to produce flocculated drilling fluids comprising micro-floccules;(c) collecting micro-floccules wherein micro-floccules agglutinate andenlarge producing solids; (d) separating the solids from the flocculateddrilling fluids; and (e) removing solids from the dehydrator system. Inan aspect, the dehydrator system comprises a solids removal system influidic communication with a core dehydrator. The core dehydratorcomprises a plurality of small deflector plaques and a plurality oflarge deflector plaques. The solids removal system comprises a largecylindrical section, a large rotating paddle, a small cylindricalsection, a small rotating paddle and a drive shaft. The drive shaft isconnected to the large rotating paddle and the small rotating paddle.The large cylindrical section and the small cylindrical section are influidic communication with the plurality of small deflector plaques andthe plurality of large deflector plaques. The micro-floccules arecollected with the small deflector plaques and the large deflectorplaques wherein micro-floccules agglutinate and enlarge producingsolids. The large rotating paddle and the small rotating paddle areconfigured to move solids from the large cylindrical section to thesmall cylindrical section and out of the dehydrator system. In anaspect, the drilling fluids are rapidly mixed creating a turbulent fluidflow. In an aspect, drilling fluids and polymer solution are mixed underturbulent fluid flow. In an aspect, turbulent fluid flow of the mixturetransitions to a laminar flow.

Further provided herein are solids removal systems for a dehydratorsystem comprising a large rotating paddle; a small rotating paddle; anda drive shaft. The large rotating paddle and the small rotating paddleare in fluid communication with core dehydrator to dispose solids fromthe dehydrator system and connected to the drive shaft. In the solidsremoval systems described herein, the dehydrator system includes a coredehydrator and a mixing unit. The core dehydrator comprises a pluralityof small deflector plaques in fluidic communication with a plurality oflarge deflector plaques. The mixing unit includes a rapid mixingmanifold in fluidic communication with a plurality of verticalflocculators.

DESCRIPTION OF THE FIGURES

FIG. 1 is a front view of the dehydrator system showing the componentsof the system as described herein.

FIG. 2 showing the mixing unit of the dehydrator system that includevertical flocculators, stir tanks, polymer and double paddle stir and amud conditioning tank.

FIG. 3A is a side view of the mixing unit. FIG. 3B depicts the verticalflocculators. FIG. 3C is front view of the mixing unit.

FIGS. 4A and 4B show a perspective view and a front view of the coredehydrator and the mixing unit.

FIG. 5 is a layout of the dehydrator system as used on a drillingplatform.

FIGS. 6A1, 6A2, 6A3, 6A4, 6A5, and 6B shows the rapid mixing manifoldwhere polymer solutions enter, mix and flocculate. The manifold has aseparation to avoid the collision of fluids at the beginning of aprocess.

FIGS. 7A, 7B and 7C show the turbulent flow mixing compartment withplate openings having a turbulent flow transition zone where linearspeed of fluid flow is reduced.

FIGS. 8A and 8B show the clarifying sediment chamber with small defectorplaques and large deflector plaques. FIG. 8A depict the drag solidtransition zone (the drag solid transition zone is the area of coredehydrator that transition from a rectangular section into a circularcone 15).

FIGS. 9A and 9B show the small deflector plaques and large deflectorplaques where micro-floccules are collected and agglutinated until theyare enlarger and precipitate.

FIGS. 10A and 10B show the fluid and micro-floccule flow pathway toachieve lowered speed.

FIG. 11 shows the gearbox that moves the solids to the circularcylinder.

FIG. 12 shows the storage drawer gearbox that allows reduction of thedimensions of the core dehydrator.

FIGS. 13A and 13B show the connector to agitator shaft with dimensions.

FIGS. 14A1, 14A2, 14A3, 14B1, 14B2 and 14B3 are the bocin required toremove the agitator shaft for proper maintenance.

FIG. 15 is the inclined palettes of axial flow having a concave shape totransport solids from the circular cone to the circular cylinder.

FIG. 16 shows the radial palettes located in the circular cycle to allowsolids to exit to the positive displacement pump lobes.

FIGS. 17A, 17B, and 17C show the drag solid transition zone fromrectangular to circular and a plurality jets for the evacuation ofsolids into the circular cone.

FIGS. 18A, 18B, and 18C show the circular cone.

FIG. 19 shows the drag solid transition zone (from rectangular tocircular), the circular cone and the circular cylinder.

FIGS. 20A and 20B show the positive displacement pump lobes where solidsare discharged to the mud conditioning tank and to cutting pools.

FIG. 21 shows two positive displacement pumps (75 and 15 HPrespectively).

FIG. 22 depicts the water transporter chambers where the small deflectorplaques and large deflector plaques are located.

FIGS. 23A, 23B, and 23C are the gatherer and distribution water channelthat transports water to both the vertical flocculators and the tanksdescribed in FIG. 22.

FIG. 24 is the water discharge valve to discharge and recirculate waterto the flocculator chamber in order to reduce the suspended solids.

FIG. 25 is the water discharge valve that evacuates the tanks of thedrilling station.

FIG. 26 shows the suction pipe for discharge of solids and to cleandehydrator.

FIG. 27 show the water distribution manifold used in the drag solidtransition zone (from rectangular to circular cone) when the operationrequired removal of solids stuck to the walls and/or to clean soliddischarge pipe(s).

FIG. 28 shows the jets for removal of solids that stick to the walls.

FIG. 29 depicts the skid to be lifted by a winch and to avoid the needfor a crane.

FIGS. 30A, 30B1, 30B2, 30B3, 30C1, 30C2, 30C3, and 30C4 show thetelescopic column used to lower the dehydrator system and to facilitateits transportation.

FIGS. 31a 1, 31 a 2, 31 a 3, and 31 b show the ears that facilitatesystem lifting

FIGS. 32A, 32B and 32C show discharge pipes simultaneously dischargingsolids with the positive displacement pump lobes.

FIG. 33 shows the flocculate chamber having valves to discharge thefloccules and re-use in a mixture with polymers.

FIG. 34 shows the water collector tanks with same volume as the stirtank.

FIG. 35 depicts the stir tanks, each with its own inclined palettes ofaxial flow and four generators.

FIG. 36 shows the mud conditioning tank with its own shakers.

FIG. 37 shows the centrifuge pumps.

FIG. 38 shows the double palette shaker within the mixing unit thatcreates axil flow and increases turbulence in order to dissolve theflocculant.

FIGS. 39A and 39B are a top view of the micro-swirls produced betweendeflector plaques that help precipitation of floccules and flow tocircular cone.

FIG. 40 is a depiction of the vertical flocculators located in themixing unit to achieve a linear but minor speed.

FIG. 41 is yet another depiction of the centrifugal pumps.

FIG. 42 shows the dehydrator on a centrifuge stand to place thecentrifuge pumps.

FIG. 43 is a picture comparing the differences of water after beingtreated on a conventional centrifugal decanter (suspended solids of 300to 550 ppm) and in the present dehydrator system where suspended solidsare about 20 ppm.

FIGS. 44A, 44B, 44C and 44D show different solids discharges. FIG. 44Ashows the sold discharged to the excavator's bucket. FIGS. 44B and 44Cshows the solids discharged to cutting tools. FIG. 44D show solidsdischarged to a cutting tank.

FIGS. 45A and 45B shows the solids discharges from the dehydrator systemdescribed in Example 1.

FIG. 46 shows a top view of the mixing unit where water flows throughthe gatherer and distributor water channel to the vertical flocculatorsand then to the water collector tank.

FIG. 47 shows the centrifuge stand.

FIG. 48 shows an aspect of the emergency exit of the dehydrator systemdescribed herein.

DETAILED DESCRIPTION OF THE INVENTION

The dehydrator systems 100 presented herein are useful in the area ofoil well drilling, and are mechanically designed to be environmentallyfriendly. The dehydrator systems 100 can process drilling fluids thatcontain crude oil traces, coming from the area of production,completion, reconditioning of wells in the oil area and industrial wastemanagement in the mining area. The described systems and methods areuseful for oil field operations and other waste water processing of highdensity type of waste.

The dehydrator system 100 comprises a core dehydrator 60 and a mixingunit 50. As shown in the figures, the core dehydrator comprises aturbulent flow mixing compartment 3, a turbulent flow transition zone 4;a clarifying sediment chamber 5 (where fluid flow is substantiallylaminar), a plurality of small baffles 6 (also referred to hereinsometimes as small deflector plaques 6); and a plurality of largedeflector plaques 7 (also referred to herein as large baffle plates). Inthe turbulent flow transition zone 4, fluid flow transitions fromturbulent flow to laminar flow. The mixing unit comprises a plurality ofvertical flocculators 32. As used herein, a vertical flocculator 32 isalso sometimes referred to as a flocculator chamber or a flocculationchamber. The mixing unit 50 further comprises a rapid mixing manifold 1.The rapid mixing manifold 1 contains drilling fluids and flocculantpolymers.

The mixing unit 50 can further comprise a water collector tank 33, aplurality of stir tanks 34 for dissolving polymer, a double paddle axialflow swirl generator and a stir tank for sludge conditioning. Each stirtank can have one or more agitators also referred to sometimes as apaddle stirrer. The mixing unit can further comprise one or more mudconditioning tanks 35 and a plurality of centrifugal pumps 36. In anaspect, the mixing unit comprises three flocculators.

As described herein and shown in the figures, the dehydrator system 100may also include: a gearbox 8 or orthogonal gearbox 8; a drawer storagegearbox 9; a connector shaft 10 in fluid communication with an agitator40; a bocin 11; a plurality of inclined palettes for axial flow 12; aplurality of radial vanes or palettes 13; a drag solid transition zone14; a circular cone 15; a circular cylinder 16; a plurality of soliddischarge pipes 17; one or more positive displacement pumps 18; one ormore water well transporters 19 (sometimes referred to herein asconveying water chambers); a distributor water channel 20; a waterdischarge valve 21 to recirculate and improve water quality; a waterdischarge valve 22 for evacuating drilling system; one or more suctionpipes 23; a water distribution manifold 24; a plurality of solid removaljets 25; and solids discharge pipe 29 in fluid communication with thepositive displacement pump 18. The dehydrator system 100 can furtherinclude a skid 26, a plurality of telescopic columns 27; and a pluralityof ears 28.

Generally, as shown in FIG. 1 and as described herein, components of thedehydrator system 100 include: a rapid mixing manifold 1; a flocculationpipe 2; a turbulent flow mixing compartment 3, a turbulent flowtransition zone 4 comprising a holes plaque where fluid flow transitionsfrom turbulent to laminator flow; a clarifying sediment chamber 5 alsoreferred to as a settler, where fluid flow is laminar; a plurality ofsmall deflector plaques 6; a plurality of large deflector plaques 7; agearbox orthogonal 8; a storage drawer gearbox 9; a connector 10 to anagitator shaft 40; a bocin 11; a plurality of inclined palettes of axialflow 12; a plurality of radial palettes 13; a drag solid transition zone14 (from rectangular to circular); a circular cone 15; a circularcylinder 16, a plurality of first solids discharge pipes 17; one or morepositive displacement pumps lobes 18 (in an aspect, 75 HP and 15 HP); awater wells transporter 19; a gatherer and distributor water channel 20;a recirculating valve to recirculate water discharge 21 (in an aspectthe valve is an 8 inch valve) 21; a water discharge valve 22 to evacuatedrilling system; one or more suction pipes 23 for fast download; a waterdischarge valve 22, a plurality of suction pipes 23 for fast download; awater distribution manifold 24 for water distribution fast download; aplurality ofjets 25 for solids removal; a skid 26 and a plurality oftelescopic columns 27; a plurality of ears 28; one or more second solidsdischarge pipes 29; an emergency exit 30 and a centrifuge stand 31. FIG.3B shows the mixing unit having three vertical chambers flocculators 32,a water tank collector 33, a plurality of stir tanks 34 to stir polymerplus double paddle stirrer axial flow; and a mud conditioning tank withits own agitator 35.

As described above, the present dehydrator system comprises a mixingmanifold 1. The mixing manifold comprises a pipe having one or morerapid mixing manifold deflector plaques 38. In an aspect, the pipe is 6inches in diameter by 0.9 meter long. In the interior of the mixingmanifold 1, deflector plaques 38 are positioned in the interior of themixing manifold 1. In an aspect, these deflector plaques 38 arestainless steel shaped as fish vertebrae. In the mixing manifold 1,drilling fluid (mud) is mixed with polymer solution. In an aspect, thedrilling fluid and polymer solution can be mixed in less than 0.16seconds. The polymer solution may enter the mixing manifold 1 from oneof the stir tanks 33. In an aspect, each tank 33 has a capacity between65-70 bbls or 68 bbls. Each tank 33 can comprise double stirrers havingthree impellers (or fins). In an aspect, the impellers can be set at 120degree angle each providing an axial flow rotating at 66 rpm. The tankfurther comprises an engine. In an aspect, the engine can provide 10 HP.Polymer solution enters a flocculation pipe 2 together with the drillingfluid (mud) from a mud conditioning tank 35. In an aspect, the mudconditioning tank 35 has a capacity of 110 bbls. The mud conditioningtank 35 comprises a stirrer double vane (i.e., three impellers (fins)angled at 120 degrees each). In an aspect the stirrer double vanerotates at 88 rpm with power proved by 10 HP engine, tank or set augerdrilling. The overall described process provides fluid comprising microflocs passing through the flocculation pipe 2, in order to assist theclumping of floc entering the turbulent flow mixing compartment 3.

From the flocculation pipe 2, flocculated drilling fluids enter theturbulent flow mixing compartment 3. Collisions occur within theturbulent flow mixing compartment wall. In order to distribute flocsfloating to bottom and sides of the turbulent flow mixing compartment 3and to allow passage into the turbulent flow transition zone 4, theturbulent flow transition zone 4 has an orifice plate that covers thecore dehydrator and downwards into the turbulent flow mixing compartment3 where flocculated drilling fluid flow transitions from turbulent flowto laminar flow and provides fluid passage in a horizontal (X axis) at aclarifying sediment chamber 5.

The clarifying sediment chamber 5 also referred to sometimes as theclarifier chamber 5 or clarifying chamber 5 comprises a plurality ofwell water transporters 19 (also referred to herein as conveyor waterchambers 16 or as transporting water chambers 19). Inside of theclarifying sediment chamber 5 are a plurality of small deflector plaques6 (also referred to as small flappers 6 or small deflector flappers). Inan aspect, each of the small deflector plaques 6 are inclined atapproximately 70 degrees. The clarifying chamber further comprises aplurality of large deflector plaques 7 sometimes referred to as largeplates 7 or as large flappers 7. In an aspect, the large deflectorplaques are each set at a 70 degree incline. Drilling fluid containingflocs from the turbulent flow transition zone 4 flows substantiallyhorizontally and substantially in laminar flow. In an aspect, fluid flowof the drilling fluid containing flocs has a linear speed approximatelyless than 0.3 m/s. Drilling fluid with flocs is distributedsubstantially uniformly in the plurality of conveyor water chambers (19)to initiate the process of collision with the small deflector plaques 6.In an aspect, there are three conveyor water chambers or otherwisereferred to as well water transporters 19 or transporting water chambers19. Here, flocs tend to go up and go agglutinating to form heavierparticles precipitated. Drilling fluids containing the light flocs riseand pass from one small plaque to another and likewise coalesce toprecipitate, fulfilling the same path which are at different heights,defining a first sedimentation process. Following this, drilling fluidstravel through each one of the well water transporter 19 (conveyor waterchamber 19) and collides with a group of large baffle plates 7 otherwisereferred to as large deflector plaques 7. The large deflector plaques 7are at the substantially the same height and use substantially the sameflow path as light and heavy flocs meet the same process that waspreviously performed using the small deflector plaques 6. For example,flocs rise, agglutinate and precipitate. Additionally, this happensbetween a plate and another plate of the same height. Micro eddiesrequire floc to descend and to obtain clear water.

If there is the presence of very light micro flocs the end of thisprocess, treated water flows to a gatherer and distributor water channel20 and subsequently a recirculating valve 21 to be recirculated back tothe vertical flocculators. In an aspect, the vertical flocculators havespeeds less than 0.11 m/s in order to improve water quality, optimizingthe consumption of flocculating polymers. The process can become acyclic process from a water collector tank 33 to the stir tank 34returning to the rapid mixing manifold 1. Lightweight floc precipitatedin the flocculator chamber 32 are sucked out by a positive displacementpump 18 and returned the rapid mixing manifold 1 to continue thedewatering process.

The water distributor channel 20 (the gatherer and distributor waterchannel 20) contains flowing treated water from the conveyor waterchambers 19. The conveyor water chambers 19 comprise a plurality ofsmall deflector plaques 6, and a plurality of large deflector plaques 7which overflow to the water distributor channel 20. This allows thedistribution of water. In an aspect, the distribution of water ishandled with butterfly valves to discharge water and recirculate it backto recirculating valve 21. To improve water quality, a discharge valve22 allows water to evacuate the drilling system. This treated water isused for drilling the first few feet of an oil well (first section) andwhere there are problems in the continuity of drilling (second section).

The dehydrator system can further comprise a double reduction gear box8. In an aspect, the gearbox 8 can provide approximately 15500 Nm torqueand works at speeds below 2 rpm. A connector is attached to a shaft to aconnector 10 and further to a Bocin 11. The gearbox 8 can bedisassembled for maintenance. When required to mobilize the dehydratorsystem further comprises a storage drawer 9 to store the gearbox 8 andreduce the overall height of the equipment and facilitates itstransportation.

The dehydrator system 100 can further comprise an axial flow pitchedblade 12 (also referred to as inclined plates 12 or inclined palettes ofaxial flow 12) that occupying most of the diameter of a circular cone15. Since the shape of the circular cone 15 is concave, solids movetowards the center of the cone 15 to the circular cylinder 16 and insideare the radial vanes 13 (also referred to as radial palettes). Hence,the circular cone 15 is in fluid communication with the circularcylinder 16. The radial vanes 13 assist to evacuate solids to theplurality of solid discharge pipes 17 and the positive displacement pump18. Solids can then be disposed at a tarpaulin pool or tank called cashtank.

The dehydrator system further comprises a drag solid transition zone 14that is in fluid communication with the circular one 15. The drag solidtransition zone 14 is sometimes referred to as a transition fromrectangular to round, a transition from rectangular to circular and/or atransition zone to circular cone 15. Solids slide via gravity from thedrag solid transition zone 14 to the circular cone 15. If solids thickand adhere to the side walls of the transition zone 14 (or in thetransition from rectangular to circular), solid removal jets 25 willactivate to move or otherwise displace solids to the circular cone 15.From the circular cone 15, solids then pass to the circular cylinder 16in fluid communication with the circular cone 15. The circular cylinder16 downloads solids having a reduced or lower humidity. In an aspect,the humidity of the solids is between 40 and 50 percent or at 47% in thesolids discharge pipes 17. Solids are subsequently be sucked out by thepositive displacement pumps 18 also referred to herein as positivedisplacement pump lobes 18.

One or more suction pipe(s) 23 are used to clean and remove solids/solidwaste from the dehydrator system. In an aspect, a first suction pipe 23a is located at a first elevated height, for example, ½h1 of therectangular cube shown in FIG. 1. In this aspect, in order to download50% of the volume of clean water that is in the rectangular cubequickly, the second suction pipe 23 b can be placed above an inlet ofthe transition zone 14 or at h2 as shown in FIG. 1. With this scheme,from 0 to 50 percent of the remaining volume of the cube containingmuddy water with traces of micro flocs may be processed. The suctionpipe 23 is connected to a water distribution manifold 24. The waterdistribution manifold has at least four functions: (1) vacating oremptying water from the rectangular cube located in h1 immediately forcleaning; (2) connects to the jets 25 to remove solids and remove solidsfound in the drag solid transition zone or for example at h2 as shown inFIG. 1; (3) the water distribution manifold 24 is connected to thecircular cylinder 16 in order to empty volume around the coredehydrator; and (4) the water distribution manifold 24 is connected tothe discharge pipe 23, proceeding open valves to remove solids from thecircular cylinder 16 toward the circular cone 15 and in order to removesolids adhered to the walls. Also, when processing the sludge product ofoil drilling is finished, valves will be opened and creating a fluidicpathway to the solids discharge pipe 29.

As shown in FIG. 1, the present dehydrator system includes a solidsremoval system where solids separate and settle inside the coredehydrator 60. Separated solids are then discharged to the solids pump17. The solids removal system includes the gearbox 8 and motor on top ofthe dehydrator system, a drive shaft 64, large rotating paddles 12 andsmall rotating paddles 13. The solids removal system moves settledsolids from the dehydrator system for disposal.

In the solids removal system, the gearbox 8 is connected to the driveshaft 64 at one end, a drive shaft first end. Radial palettes 13 orsmall rotating paddles 13, collectively referred to as a “small rotatingpaddle” are connected to the draft shaft 64 at the other end of thedrive shaft 64, a drive shaft second end, and positioned within thecircular cylinder 16 (also referred to as a small cylindrical section16). Furthermore, the inclined palettes of axial flow 12 or largerotating paddle 12 is also connected to the drive shaft 64 between thedrive shaft first end and the drive shaft second end. The large rotatingpaddle is positioned within the circular cone 15, also referred to as alarge cylindrical section. The large rotating paddle moves solids fromthe large cylindrical section 15 to the small cylindrical section 16which is in fluid communication with the solids pump 17 via one or moresolids discharge pipes 17. The large rotating paddle 12 may optionallyinclude a rubber paddle attachment (not shown) at the end of the largerotating paddle or a free end of the large rotating paddle that is notconnected to the drive shaft 64.

In an aspect, jets can be used for removal of solids 25. The jetscomprise one or more pipes located between flocculation pipe 2 and theturbulent flow mixing compartment 3 as shown in FIG. 1. Thisconfiguration allows for removal of adhering solids at the bottom ofturbulent flow mixing compartment 3. A plurality of jets 25 located inthe drag solid transition zone 14 (inlet of solids from rectangular toround), can further remove solids adhered in the circular cone 15. Jetscan also be positioned in the small cylindrical section 16 near thesolids exit of the small cylindrical section 16, in the solids dischargepipe 17 and/or the solids pump.

The dehydrator system 100 can further include a travel unit having askid 26 anchoring the turbulent flow transition zone 4 and plurality oftelescopic columns 2 so that the dehydrator system can slide upward whenoperations are started. The unit can further decrease height for movingit and to meet standards for heavy loads on the roads. When enteringareas inaccessible by road, the present dehydrator system can be movedby helicopter using the following: crane gauges connected in the ears 28where equipment continues to life and the pins of each of the telescopiccolumns 27 are removed. By tapping and lifting, the system is separatedit into two parts. The first part is the skid 26 which contains twopositive displacement pumps 18, centrifugal pumps 36, the waterdischarge manifold 24, pipes, hoses and other accessories. The secondpart is the remaining portion of the system including its beams.

The dehydrator system described herein can operate at a noise level nearzero decibels (dB), contributing to environmental protection. Thedehydrator system can continuously process at flow rates of less thanapproximately 1200 gpm between drilling fluid (mud) and polymersolution, without suspending the process of dehydration. Solids can beremoved directly from the dehydrator system without requiring additionalequipment to dewater solids. Solids can be sent directly to the finaldisposal having humidity as low as 40 to 45 percent and possible lowerbetween 25 and 35 percent or 25 and 50 percent. In the presentdehydrator system, the core dehydrator is combined with a mixing unithaving a plurality of vertical flocculators to process fluidscontaminated with traces of crude product of oil drilling and to collectsolids manually in a similar way as an API trap. In the describeddehydrator system, there can be 1 to 15 flocculators, 3 to 11flocculators, 3 flocculators or any other number of flocculatorsnecessary to provide the quality of water treatment desired. The presentdehydrator system can suck sand, coarse solids, clays, shales, directlyfrom the sand trap drill hole located under the shakers. This avoidspassing the solids to the other tanks in the system drill, avoidingpumps and other equipment damaged auger drilling and also save theconsumption of meshes for sieves. (See FIG. 1).

The quality of treated water provided by the core dehydrator anddehydrator system relates to the depth of the feet drilled oil wells,ranging from 0 to 6000 ft approximately (1st section). The result ofsuspended solids can be less than 25 mg/l at the water discharge valve22. If it is necessary to improve the quality of water, it can be passedthrough the recirculating valve 21 to the flocculator chamber 32 toobtain clearer water at the water collector tank 33 with suspendedsolids below 18 mg/l. For ranges between approximately 6000 to 9800 feet(2nd Section), suspended solids of less than 85 mg/l in the outlet canbe obtained at the water discharge valve 22. If necessary to improve thequality of water, it can pass through the recirculating valve 21 to theflocculation chamber 32 to obtain higher quality water in the watercollector tank 22 having suspended solids below 72 mg/l. Finally, forranges between 9800 to approximately 12,000 feet (3rd Section),suspended solids of less than 650 mg/l in the outlet can be obtained atthe water discharge valve 22 and if It requires improving the quality ofwater pass through the recirculating valve 21 to rapid mixing manifoldto improving quality in the water collector tank 33 having suspendedsolids of approximately less than 500 mg/l.

The present dehydrator systems can flocculate and dehydrate drillingfluid with densities ranging from about 1030 to 1450 kilograms permeters cubed (Kg/m³) and provide drilling wastewater in condition forrelease into the environment without substantial pollution. Thedehydrator system can receive water-based fluids from drillingprocesses, which contain very high densities, otherwise referred to as a“mud” and drilling fluid that is mixed with the solids inside a hole,sometimes referred to as waste. The dehydrator system can be furtherused to receive fluids contaminated with hydrocarbons (high totalpetroleum hydrocarbon (TPH)), from formation waters for treatment, orproduction sands when drilling is taking place. These dehydrator systemstend to avoid or mitigate environmental impact.

The dehydrator systems described have certain advantages including adecrease in the measurements of the deflector plaques, an increase andnovel shape of stirring blades, an increase in the capacity of reducingboxes (gearbox), and unique placement of jets in corners to facilitatesolids fall. In addition, the dehydrator system has a plurality offlocculators (in an aspect, three flocculators) each positioned in aflocculator chamber and each flocculator having optimized inclinationangles, including both ends as a cone, and location of additional jets.

Also, in an aspect, the dehydrator systems described herein have therapid mixing manifold positioned in the mixing unit that is directlyequalized with the core dehydrator. In an aspect, the mixing unitcomprising three vertical flocculators 37, a water collector tank 33,which has the same capacity as the tank for polymer dissolution, twotanks for polymer dissolution (also referred to as polymer stir tanks)each tank having an agitator (i.e., double paddle stir), and a mudconditioning tank 35 with an agitator. In the rapid mixing manifold 1having inlet deflectors, drilling fluid is mixed with polymer flocculantpolymer solution, and in some aspects, in less than a second. In anaspect, the inlet deflectors have a fish vertebrae shape. This way, theflocculated mud enters a turbulent flow mixing compartment 3 in which acollision with the compartment wall is produced, and in order todistribute the flocs on the bottom and sides of the compartment 3allowing immediate precipitation of solids.

In the interior of each chamber, there are a plurality of smalldeflector plaques 6 and a plurality of large deflector plaques 7, eachtype of plague can be inclined at 70 degrees. At this point in theprocess, drilling fluid containing flocs has a laminar flow and moveshorizontally with linear speeds of less than 0.3 m/s. Therefore,drilling fluid is distributed substantially uniformly in each of thechambers, beginning the process of collision with the small plaques 6 inwhich the flocs tend to go up and joining together to form heavierparticles that precipitate. The fluid that contains the light flocsrises and passes from one plaque to another, where they also agglutinateto precipitate, fulfilling the trajectory of the plaques that are foundat different heights, to meet the first sedimentation process.

Following this, fluid travels through each one of the flocculators andcollides with the first plaque 7 a of the plurality of large deflectorplaques, the same are at the same height and on the same path of thelight and heavy flocs meet the same process as was done in the smallplaques 6, i.e. as they ascend they agglutinate and precipitate. Inaddition to this process, between each plaque of the same height, microwhirlpools are generated, requiring floc to descend, to obtain clearwater. If at the end of this process, there is possibility of presenceof very light micro flocs, water can be collected in a water channel,that will subsequently flow to the flocculators, located in the mixingunit which is intended to improve water quality. As a result of thisprocess, a certain volume of water can be obtained that is used toprepare the polymer solution, a cyclical process, and finally returningto the core dehydrator to continue the dehydration process and the otherpart will go to a storage tank for final disposal that is thereinjection.

In the distributor water channel 20, fluid (water) comes from aplurality of well water transporters 3, each having plaques in theinterior. Water falls due to overflow, and as its name says, allowswater distribution through a plurality of butterfly valves, distributedby the water discharge valve 22 to improve water quality and one waterdischarge valve 22 to evacuate the perforation system where water isused for the first feet of perforation of an oil well (first sectionfrom 0 to 6000 ft.), and when problems arise in perforation continuity(second section from 6000 to 9000 ft.).

In the core dehydrator, there is a double orthogonal reducing box(gearbox) 8 providing a 15,500 Nm torque that works at speeds of lessthan 2 rpm, joined to a connector 10 to the agitator that is easy todisassemble for maintenance. When the core dehydrator has to be moved,it has a storage drawer gearbox 9, allowing total reduction of heightand to facilitate transportation of such equipment. A reducing axledirectly attaches to the deflector plaques 6, 7, of axial flow,occupying 99% of the cone diameter, its concave shape allows easilymoving the solid to the center of the cone, to a circular cylinder 16inside of which the radial palettes 13 are found that help evacuatesolids through a plurality of solid discharge water ducts and then topositive displacement pumps. Solids will be placed on an impermeablepool or a cutting tank referred to sometimes as a cash tank.

The drag solid transition zone 14 allows solids to slide by gravity tothe circular cone 15 and in case that solids are clay like, and adhereto the lateral walls in the transition zone 14. A plurality of jets 25can be activated to help solids to move, and then pass through thecircular cylinder 16 that allows solid discharges with humidity of lessthan 47% and be further suctioned by positive displacement pumps.

Furthermore, there are discharge suction pipes 29 for solid wastecleaning and removal from the dehydrator system. The first pipe islocated at about ½ of h1 (FIG. 1) from the rectangular cube of the coredehydrator, with the purpose of discharging 50% of the clean watervolume that is found in the rectangular cube in a quick manner, and thesecond suction pipe is found 10 cm above the drag solid transition zoneh2 (FIG. 1), to eliminate substantially 50% of the volume of the cube,that contains dirty water, with traces of micro floccules. The suctionpumps are attached to the water discharge manifold 24 that has fourfunctions: first, evacuate all the water from the rectangular cubelocated in h1, immediately for cleaning; second, connect the pluralityof jets for solid removal; third, connect to the circular cylinder 16,with the purpose of evacuating 100% of the volume on the core dehydratorand fourth, connect to the disposal pipes, opening valves to removesolids from the circular cylinder to the cone in order to remove solidsadhered to the walls, and so, when all the mud from the oil perforationis removed, valves are opened directing them to a solid waste dischargeduct, and water is pumped until it comes out totally is solid-free.

The skid 26 secures telescopic columns 27 that help to slide ascendantto the core dehydrator when perforation operations start, and descendwhen we are going to transport, to reduce height, to comply with heavyload regulations. When the equipment goes to inaccessible places byland, it may be transported by helicopter, for this purpose thefollowing procedure must be followed: crane gauges of a crane must beconnected to the ears 28, keep system raised until the pins of each ofthe telescopic columns 27 are removed, by slightly striking; then thecore dehydrator is raised completely, separating it into two parts: theskid, which has two positive slide pumps, centrifuge 4×3×13 pumps, waterdischarge manifold, ducts, hoses and other accessories; and the upperpart of the core dehydrator including its beams.

The result of processing mud using the described dehydrator systemsinclude:

Solids with average humidity of up to 47%, and that are easilytransported through pipes except the solids coming from the decantedcentrifuges.

Free particle water with suspended solids within the limits allowed bythe Environmental Legislation, for those fluids from the firstperforation section.

Distribution of the more compact solids in cells or pools.

Advantages of the dehydrator system include new parameters for this typeof equipment, regarding height and length, facilitating movement,transportation, and placement, related to the core hydrator, being atotally compact equipment.

LENGTH OF EQUPMENT 8.454 m HEIGHT (Without cealing) M

Another advantage is construction of a stand in the same unit, to placea decanter centrifuge, with the purpose of removing or recuperating lowor high gravity solids. In one aspect of the described dehydratorsystem, the deflector plaques 6, 7 have inclination at 70 degrees andcomprise aluminum material having raised thickness from about 4 to 6 mm.The deflector length can be diminished, that is a height of 1.7 metersfrom the cylinder versus a 2.3 meters height over the same cylinder.Also, in an aspect, the transition zone 4 is constructed with ASTM A36steel thickness with an angle of 33.67 degrees on the side and 51.34degrees in the center. The diameter of a precipitation cone of thetransition zone 4 is 3.2 m. A height of 700 mm was built in an aspect ofthe transition zone 4 made of ASTM A588 steel with 6 mm thickness, and a27.7-degree angle formed from the top part of the solids discharge. Thecircular cylinder 16 can have a height of 24 cm, with a connection thatallows the flow of solids with a certain degree of inclination. Therapid mixing manifold 1 is located in the mixing unit and between about6 to 8 meters from the entrance to the core dehydrator in order toflocculate the mixture and agglutinate it during transportation.

In the present dehydrator system, water exhaust channels are eliminatedin the compartment of the sediment settler chamber in order to have alonger residence time and get better water quality. Solids controlprocesses can be different now in the oil industry as the coredehydrator is friendly to the environment. Currently, the use ofdecanter centrifuges in the process of dewatering or dehydration isparamount in drilling (conventional solids control process). The presentdehydrator system uses an additional decanter centrifuge for the processof removal of low or high gravity solids, allowing the customer savingsin their operations costs such as fuel consumption, and maintaining ingood condition the properties of the drilling fluid, decreasing thedrilling days. Other secondary but important issues for the operator isthe decrease of use of chemicals, of mesh screens within the drill,because the equipment will optimize the use of such materials.

The subject dehydrator systems can process waste at high flow rates,resulting in water with optimum parameters to be reused or sent forreinjection wells and/or solids that are easy to be transported ordisposed. Energy consumption is lower with the dehydrator system,therefore the cost to rent a power generator necessary to operate it,and diesel consumption are lower, also helping to minimize environmentalpollution. The system is transportable and can be assembled anddisassembled. With the present dehydration system, the time in settingup in rig up and rig down has been reduced in comparison to othersystems. In a second stage, if the pools or cells where the cuttings andwaste are deposited are near the dehydrator system, the road equipmentsuch as excavator and dump trucks, can be minimized or eliminated, asthese would be driven by two positive displacement pumps, and can bedistributed throughout the pool, by transport pipeline of 6 or 8 inchesthat would be located around the dehydrator system.

In the development of the dehydrator systems, a first prototype wasdesigned and built. The prototype measured are (2.4 m long×0.7 m wideand 1 m high), and had a 6-month test in exploitation oil fields,resulting in improved efficiencies in the processes of dehydration(sometimes referred to as dewatering), whether toward the active system(returning water to the drilling tanks) or discharge of the water to theenvironment.

Treated water obtained from the dehydrator system can result insuspended solids at 20 mg/l in the first section of drilling, whereaswith conventional equipment suspended solids results range from 240 mg/lto about 480 mg/l, saving chemicals to treat wastewater from the saidequipment, sending the water directly to injection, complying with thevalid parameters set by law, without chemical treatment. The results ofsuspended solids from water in the second and third sections of thedrilling can be less than 500 mg/l, compared with the conventionalsystem which ranges from 2500-8000 mg/l.

Using the present dehydrator system, processing of the mud or fluid tobe treated is continuous, without stopping the dehydration process formaintenance, as the conventional system has to stop operations at least2 times every 24 hours for a period of 2 hours. In the present system,fluid flow is substantially constant. Fluid flow speed changes at theend of the process (where flocculators are located in the mixing unit)can be less than 0.1 m/s to aid micro floccules to clump together andprecipitate and obtain clear water. The present dehydrator system hasthe capacity to suck sand, thick solids, clay, directly from the drillsand trap drill or grit chamber; compared with other solids controlequipment that has to be suctioned when the fluid is completely clean ofsand and clay (after the de-claying tank of the drill) (FIG. 3) to avoiddamaging the internal part of the decanting centrifuges. Using thepresent, an operator may omit the use of a sludge conditioner,representing a considerable financial saving.

The total flow is designed to process is approximately 1200 gallons perminute (gpm), between drilling fluid (mud) and polymer solution; whileprior art solids control system processes up to 450 gl/min betweendrilling fluid and polymer solution. There is a relatively lowmaintenance cost for the present dehydrator system compared to decantingcentrifuges or conventional system. There is a decreased consumption ofmeshes in the shakers of perforation drills, especially in the firstsection (0-6000 feet); an analysis made from 2011 to 2015, obtained a42% savings, using the dehydrator system descript, compared to othersystems. Furthermore, there is a reduced chemical consumption; ananalysis was done from 2011 to 2015, and it was optimized by 50%compared to the conventional system. The present dehydrator system canremove oil traces, especially in oil fields that use the equipment. Thedehydrator system reduces or minimizes environmental pollution andindustrial safety in noise reduction (according to the noise map). Theresult was zero decibels, with other solids control equipment there isan average of 85 to 110 dB.

The present dehydrator system can also be used in the mining area,wastewater plants, and for water under formation. Formation water thatcomes with sand, solids and traces of oil can be treated; as well asfluids from the mining industry, since using the system optimizes theuse of the sieves and hydro cyclones. Solids are drawn out and clearwater obtained that is returned back to the active system, or to theprocess, avoiding water discharge to the environment. The presentdehydrator system continuously, without stopping, evacuates solids ordense flocs, as well as treated water, and this allows to avoid problemsthat oil and mining industries are currently having, such as the storagevolume of weak solids that occupy more volume and therefore greatercapacity in pools or tailings.

The dehydration system and processing involve dehydration of thedrilling fluid in oil wells to produce a liquid (water) and solid (cuts)discharge. Dewatering processes are performed and the resulting fluidcan be routed to the active system or towards the water treatment tanks,depending on the conditions in the perforation. The dehydrator system100 utilizes a process of chemical and physical separation (volumetricreduction). Dehydration of the cuts is essential for treatment in poolsor cells reducing capacity of them. This operation will be carried outby sedimentation baffle plates. Prior to the discovery of this process,a chemical compound that destabilizes the emulsion that forms the mud,and promotes the chemical and physical separation of its components willbe added.

The present system applies solids controls processes without usingcentrifuges decanters, a dewatering unit or dehydrator, and caneliminate excavators and dump trucks, especially where there are poolsnear the location. If the process works with cells or storage centers,tank cuts or cash tanks will be used. It can obtain improved waterquality so that water can be reused in the active drilling system, inorder to prevent colloids which in turn degrade, when passing throughthe drill pipe, increasing the viscosity in the drilling fluid, and thusincreasing the operation days. As noted herein, it can help decreaseelectrical energy consumption, saving 27% on fuel in comparison to othersolids controls processing and minimize the environmental impact causedby the discharge of liquids to the environment while reducing the noisecaused by conventional equipment (80-110) dB to zero (0) dB with the DNTequipment. FIG. 3 details the layout of an aspect of the dehydratorsystem 100 discussed below in Example I.

Example I Parameters and Main Components of the Dehydrator System

TABLE 1 SYSTEM PARAMETERS Maximum load 32869 kg Work flow (approximate)1200 gal/min Volume of the equipment 300 bbls Length of the equipment8.454 m Width of the equipment 3.56 m Height of the equipment withcealing 7.450 m Height of the equipment without cealing 4.650 m

TABLE 2 PARAMETERS OF THE MIXING UNIT Maximum load 20464 kg Work flow(approximate) 1200 gal/min Volume of the equipment 964 bbls Length ofthe equipment 7.654 m Width of the equipment 3.2 m Height of theequipment ceiling 6.253 m included Height of the equipment withoutceiling 3.408 mStand for Decanter Centrifuges 31

A stand 31 was built, in order to place a decanter centrifuge and tosupplement the core dehydrator and perform the removal of solids of lowand high gravity. (See FIG. 47)

Telescopic Columns System 27

The telescopic columns system comprises a set of four bases, boot anddetachable column with pin. Boots constructed with ASTM A36 steel 12 mmthick, were reinforced with square stiffners flange type, reinforcedwith ASTM A 36 steel 16 mm thick, for reinforcement between skid baseand boot (see FIG. 30).

Columns and Side Beams

The columns support the weight of the structure plus weight of the fluidwhen in operation, it is composed of a UPN profile 200, final dimensions200×150 mm and 3800 mm high, design load 20,000 Kg compression. Sidebeams UPN profile 140 mm, on which a vessel lining, ASTM A36 steel 6 mmthick, is attached.

Ears 28

A plurality of ears 28 were built in order to help demobilize anddismantle of the equipment, built with NAVAL steel material, with ayield strength of 248 MPa and a thickness of 39 mm; this element asshown and described can support 26 tons (see FIG. 31).

Container Cover

The container cover was made of ASTM A36 steel material having athickness 6 mm, and side measures: 4000 mm×2500, depth 1700×2500 mm.(FIG. 2).

Fluid Inlet Manifold

Dehydrator system has a rapid mixing manifold 1 with inlet deflectors,where drilling fluid (mud) is mixed with flocculant polymer solution,and moves in the pipe 2. The mixing manifold 1 is located on top of themixing unit (See FIG. 6).

Flocculation Pipe 2

In an aspect, the flocculation pipe 2 is built with steel SCHapproximately 80 8 m length which function is to allow clumping floc toenter the chamber 5. Drilling fluids enter the core dehydratorflocculated (See FIG. 3), and the turbulent flow mixing compartment 3.

Turbulent Flow Receiver Mixing Compartment 3

In this aspect, the compartment 3 was made of ASTM A36 6 mm thick steel,curve plaque radius 1780 development 4000 mm, where the flocculateddrilling fluid enters, and a collision with the wall of the compartment3 occurs. (FIG. 3), distributing the fluid both at the bottom and at theside. (See FIG. 7)

Turbulent Flow Transition Zone 4 (the Holes Plaque)

In this zone, perforations of 300 and 250 mm in diameter in the plaguewere made (See FIG. 7). Due to its shape, fluids pass from turbulentflow to laminar flow to cover the entire width of the equipment.

Clarifying Sediment Chamber 5

The clarifying sediment chamber 5 is the main chamber where solids cansettle in one of three water transportation chambers. The clarifyingsediment chamber has small and large deflectors to allow for a laminarflow for the proper settling of floc and heavier particles, such assand, clay and gravel, in order to improve residence time and obtain abetter water quality (See FIG. 8).

Small Deflector Plaques 6

Small deflector plaques 6 were set in this aspect with inclination angleof 70 degrees, and having sliding, steel material, 6 mm thickness,placed at different heights, where flocs tend to rise and agglutinate toform heavier particles that fall. (See FIG. 9).

Large Deflectors Plaques 7

Large deflectors plaques 7 were set at an angle of 70 degrees in thisaspect, sliding material, 6 mm thick, aluminum, with a length of 1.7 m,placed at 2.3 m from the base where solids output. (See FIG. 10)

Reduction Gearbox 8

Double orthogonal reducer gearbox 8 can work at speeds below 2 rpm. (SeeFIG. 11).

Storage Drawer for Gearbox 9

Built specifically to keep the gearbox 8 and allow the reduction ofoverall height of dehydration system, facilitating transportation ofequipment. (See FIG. 12).

Connector to Agitator Shaft 10

The connector to agitator shaft 10 provides transmission of power andmotion. Made of steel material AISI 1045 HR, yield strength of 313 MPa,has a towing capacity of 122 kgf in each of the ends of the sweepers,and can withstand without difficulty a maximum torque of 3841 Nm withoutdamage occurring. (See FIG. 13)

Bocin 11

The bocin 11 is an element that supports cut, due to torsion, thus ithas a yield strength 431.6 MPa, an outer diameter of 112 mm, innerdiameter 63 mm. (See FIG. 14).

Inclined Palettes of Axial Flow 12

The purpose of the inclined palettes of axial flow 12 are to remove thesolids deposited in the system located at the ends toward the center andat full capacity. The inclined palettes of axial flow 12 is a pluralityof inclined palettes rotating with helped of the orthogonal motorreducers. In this aspect the inclined palettes of axial flow rotate at 1to 2 rpm, 21500 Nm approximately, working 24 hours a day, and with about15 HP. (See FIG. 15)

Radial Palettes 13

The purpose of the plurality of radial palettes 13 is to evacuate thesolids (deposited in the cylinder) and move solids towards the solidsdischarge pipe 17. (See FIG. 16)

Drag Solid Transition Zone 14—from Rectangular Section to Circular Cone

The drag solid transition zone 14 is a rectangle section of the coredehydrator positioned adjacent to the circular cone 15. In an example,the drag solid transition zone 14 was sized at 4000×3200 mm in rectangleshape and built in ASTM A 36 6 mm thickness, emergency hatch 700 mm×400mm, with top angles of 33.67° and 51.34° at the bottom. (See FIG. 17)

Circular Cone 15 or Large Cylindrical Section 15

The circular cone 15 allows solids to move to the circular cylinder,made of steel A588 diameter of 3.2 m with a height of 700 mm 6 mmthickness, with 27.7° angel, taken from the upper part of the soliddischarge. (See FIGS. 18 and 19)

Circular Cylinder 16 or Small Cylindrical Section 16

The circular cylinder 16 also referred to as the small cylindricalsection 16 allows discharge of solids having less than 47% humidity tobe suctioned by positive displacement pumps or lobes.

Solids Discharge Pipe 17

Solids discharge pipe allows output of dehydrated solids for finaldisposal; the material is SCH 80.

Positive Displacement Pumps 18

Positive Displacement Pumps 18 evacuate solids. In this aspect, therewas a pump 18 of higher potency for chamber use, and another of lesspotency as contingency for maintenance. The chamber uses 1 Borguer 75 HPpump in which the curve is attached. The pump 28 with less capacity todischarge flocs coming from vertical flocculators and send to the coredehydrator. (See FIG. 21)

Water Well Transporter 19 (Also Referred to as Water Transport Chambers)

In this aspect, three water transport chambers are constructed in ASTMA36 steel were used in this example; in which interior there are smalldeflector plaques, inclined at 70 degrees and large deflector plaquesinclined at 70 degrees the fluid containing flocs, which flow is laminaris moved horizontally, with linear speeds of less than 0.3 m/s. Thefluid is uniformly distributed in three water well transporters (watertransport chambers) and overflows through the collector and distributorchannel. (See FIG. 22).

Collector and Distributor Water Channel 20

The collector and distributor water channel (also referred to as thegatherer and distributor water channel) collects overflow fluid from thetransport water chambers 19 which contain the deflector plaques 6, 7,and overflow travel to the same. As its name indicates, the channel 20allows distribution of water through the operation of a plurality ofbutterfly valves. In this aspect, eight-inch valves were used. One valverecirculates water to improve water quality. Another valve is used forwater discharge to evacuate to a drilling system (See FIG. 23).

Water Discharge Valve 22 a to Improve Water Quality

An ANSI 150 valve 22 a was used to recirculate water, improve waterquality, passing through the vertical flocculators. (See FIG. 24).

Water Discharge Valve 22 b to Evacuate Drilling System

A water discharge valve 22 b to evacuate the active drilling system. Thewater can be used for drilling the first few feet of an oil well (firstsection) and when there are problems in the continuity of drilling(second section). (See FIG. 25).

Suction Pipes 23 for Rapid Discharge to Clean the DNT

Suction pipes 23 allow for cleaning and removal of waste solids from thedehydration system. In an aspect, a first pipe 23 a was located ½ h1from the rectangular cube of the dehydration system. In order toevacuate quickly, 50% of the volume of clean water that is in therectangular cube. A second pipe 23 b is 10 cm above the Drag SolidTransition Zone 14 to move and remove the other 50% of the volume of thecube containing turbid water with traces of micro flocs. (FIG. 26).

A Plurality of Jets 25 for Solids Removal (Solid Removal Jets 25)

The jets 25 remove solids found in the transition zone 14 fromrectangular to circular. (See FIG. 28).

Skid 26

In an aspect, the skid 26 supported 60 tons distributed: 30 tons in thecentral part and 15 Tons at each end. The skid 26 made up of five beams,eight crossbeams HEB 200 mm, round tube diameter 6″ SCH 80 for skidpuller, cover for platform 10 mm thick, steel 505, weight of 4200 Kgskid structure distributed (See FIG. 29).

Solids Discharge Pipe 29

In an aspect, the pipe for solids discharge (solid discharge pipe 29) ismade in SCH 80 to discharge solids, final product of dehydration. (SeeFIG. 32).

Emergency Exit 30

An emergency exit 30 for personnel can be designed if required (See FIG.48)

Supplementary Equipment

In addition to a core dehydrator, the dehydrator system 100 includessupplementary equipment comprising the mixing unit where chemicals andflocculant polymers are mixed to obtain a homogeneous mixture. In themixing unit, the homogeneous mixture be can further mixed with thepolymer solution and drilling fluids from oil wells. The mixing unitincludes the following:

Flocculators Chambers 32

In this example, there are three flocculator chambers. The material inwhich it is built is naval steel; the travel speed is less than 0.1 m/s,helping to aggregate the micro-floccules (“micro-flocs” or “microflocs”)in larger flocs, and at the same time serves as an API trap to removetraces of crude; the sediment flocs are suctioned by the small positivedisplacement 15 HP pump, and returned to the dehydration process. Theclear water passes to the collector tank. (See FIG. 33).

Water Collector Tank 33

In the water collector tank 33, a polymer solution can be prepared orstored. A centrifuge pump of 4×3×13 having 25 HP engine and impeller of10.5″ or a 5×5×14 pump was used in an aspect. (See FIG. 34)

Polymer Dissolver Tanks or Stir Tanks 34

Each stir tank 34 has an agitator double palette axial fluid and fourwhirlpool generators. In an aspect, two stir tanks 34 for dissolvingpolymers were used; each one would have a double palette agitator (3wings placed al 120° each) (See FIG. 38), with a 55 HP engine at 88 rpm.The residence time to dissolve the polymer would be from 20 to 35minutes; to send the polymer solution to the fast mix manifold, acentrifuge pump 4×3×3 with a 25 HP engine, is needed. (See FIG. 35)

Mud Conditioner Tank 35, with its Respective Double Palette Agitator

The mud conditioner tank 35 homogenizes drilling fluids (mud), regulatespH, and coagulates particles. The tank 35 comprises a double paletteagitator (3 wings placed at 120° each) (See FIG. 38), with a 10 HPengine, at 88 rpm. Out of this tank 35, mud is sent to the rapid mixingmanifold 1 where mud mixes with the polymer solution. For this purpose,a centrifuged pump can be used. (See FIG. 36)

Centrifuge Pumps 36

In an aspect, centrifuges pumps 36 are 4×3×13 with a 25 HP engine and10.5″ diameter. These pumps 36 allow transportation of mud flow or thepolymer solution. (See FIG. 37).

The present dehydration system dehydrates perforation flow (mud) havingdensities from about 8.6 to 12.5 lb/gl to obtain a liquid discharge(water) and solid (cuts). The products resulting by use of thedehydration system 100 can be forwarded to the active system or to watertreatment tanks. (See FIG. 5). The present dehydration systems includethe rapid mixing manifold having a plurality of inlet deflectors, wherethe drilling fluid (mud) and the solution of flocculant polymer ismixed. In this way, entering the core dehydrator, the drilling fluid isalready flocculated. Through the first compartment, due to its shape, itallows to have a turbulent flow regime for better agitation and mixingof mud polymer. Subsequently, the fluid passes through circular holes inthe turbulent flow transition zone (zone transition from turbulent flowto laminar flow) to the chamber where solids settle within the chambershaving both small deflectors and large positioned at angles greater than60 degrees and less than 90 degrees (for example 70 degrees has beenshown to work well) by distribution, allowing laminar flow for propersedimentation and clumping of heavier particles such as sand, clay andwaste. As a result of this processing, water free of particles at thetop and suspended solids vary according to each operation, but betweenabout a range of 1 to 500 mg/L and the bottom solids with humidity lowerthan 50 percent, for example 47%.

Calculation of Drilling Fluids and Waste Inflow from Perforation Processfor Positive Displacement Pump

For calculation purposes, the following information was considered:

Total fluid flow of the system 100 is approximately twelve hundredgallons per minute (1200 gpm) of mud plus polymer solution. Solidsgenerated can be transported by the larger capacity Borguer pump.

Calculation a Drop of 300 ft/hour, 16″ Diameter and a 20% WS wasConsidered to Calculate Flow and Mass Flow

$V = {\frac{3.1416*D\; 2}{4}*h}$$V = {{1423\mspace{11mu} m\; 3*\frac{6.28\mspace{14mu}{bbls}}{1\; m\; 3}*\frac{42\mspace{14mu}{gl}}{1\mspace{14mu}{bbl}}} = {3753\mspace{14mu}{gl}}}$$Q = \frac{V}{t}$$Q = {\frac{3753{\mspace{11mu}\;}{gl}}{60\mspace{14mu}\min} = {62.6\mspace{14mu}{gl}\text{/}\min}}$Solids Generated by the Bit

${CAPACITY} = {{\frac{0.98\mspace{14mu}{bbl}}{300\mspace{14mu}{ft}}*0.0033\frac{bl}{ft}} = {1.71\mspace{14mu} L\text{/}m}}$$\frac{300\mspace{14mu}{ft}}{h} = \frac{91.44\mspace{14mu} m}{h}$${{SOLIDS}\mspace{14mu}{DENSITY}} = {21.66\mspace{11mu}\frac{LB}{GL}}$${FLUJOMASICO} = {{\frac{1.71\mspace{14mu} L}{M}*\frac{91.44\mspace{20mu} M}{H}*\frac{1\mspace{14mu}{GL}}{3.7858}*\frac{21.66\mspace{14mu}{LB}}{GL}*\frac{1\mspace{14mu}{KG}}{2.2\mspace{14mu}{LB}}} = {{404\mspace{14mu}{KG}\mspace{14mu}\left( {50\%\mspace{14mu}{humidity}} \right)} = {202\mspace{14mu}{kg}\text{/}h}}}$

Additional Equipment

A Borger pump model FL 518 of 75 HP is used to evacuate solids of thesieves and of the mud conditioner, towards the cuttings pool (graph28/31 and 29/31)

Drilling Cuts Management

Waste and cuttings produced by the DNT would be driven by two positivedisplacement pumps; they would be distributed throughout the pool sincetransport would be done on a 6″ pipe that will be extended around thepool perimeter. One of the benefits is that conditioner cuttings aretransported to the conical pocket shakers by a worm screw and from therethey are collected and transported along the pool (graph 30/31 and31/31).

Wastewater Management

Wastewater obtained from the DNT will recirculate through a closedcircuit to the active system of tanks of the perforation drill and whenit is no longer reused is will be sent to the Water Treatment System tobe conditioned to comply with Environmental Law, for subsequentdischarge or injection.

Tests

The results of our testing were partial in the first test well, theresults by sections product of the perforation are listed in Table 3below.

TABLE 3 Tests for the Dehydrator System Suspended Solid (TSS) MudDensities and Humidity Perforated And Turbidity (NTU) Flows* of theDischarges feet Date Time Properties of Mud Mud Solids or Cuts WaterDepth Day/Mo/ Hour/Min/ μ P Intermediate Final Q(G) P Retort A P (ft)Year sec cps Ppg Mgl Mgl NTU Min ppg (ml) Humidity ppg 450 1 Jun. 2012 7:20:00 30 8.9 7.4 31 31 18 0 0 555  8:45:00 30 8.9 7.4 9 5 4.09 18 284.31 700 10:17:00 30 8.9 7.4 5 5 2.8 11.4 950 13:40:00 30 8.9 7.4 2 00.73 11.5 1055 15:10:00 30 8.9 7.4 2 0 0.8 11.6 1200 16:41:00 30 8.97.12 4 0 0.61 11.3 1450 20:05:00 30 9.1 7.1 2 0 1.13 11.4 2060  2:00:0030 9.2 7.3 1 0 0.76 11.5 24.5 2535  8:00:00 30 9.3 7.4 5 0 2.77 11.72750 10:05:00 30 9.3 7.4 11 1 1.59 11.5 25 36.2 8.33 3000 12:30:00 309.3 7.4 5 1 1.97 11.4 3250 14:05:00 30 9.3 7.4 14 6 4.19 11.7 350016:18:00 30 9.5 7.4 16 7 2.64 11.7 27 38.4 8.33 3750 19:03:00 31 9.5 7.412 0 1.17 11.7 4000 2 Jun. 2012 21:12:00 31 9.5 7.4 9 0 1.02 11.5 4600 2:00:00 32 9.7 7.4 6 5 4.12 11.7 4989 18:00:00 30 9.8 7.23 4 4 4.1211.6 33 47.3 8.33 5200 20:00:00 30 9.8 7.25 5 3 5.1 11.6 5550 3 Jun.2012 23:10:00 31 9.8 7.31 7 4 5.83 5700 13:00:00 33 10.2 7.35 15 8 5.185977 4 Jun. 2012 17:00:00 35 10.4 7.39 8 2 3.21 11.7 25 37 8.33 AVERAGEAT LOW FLOW 8.24 3.90 3.41 19:30:00 35 10.4 8.24 38 30 19.3 11.4 8.3320:21:00 35 10.4 8.24 29 19 10.9 5977.0 5 Jun. 2012 21:35:00 35 10.48.24 35 24 15.1 22:00:00 35 10.4 8.24 37 12 9.02 5977.0 6 Jun. 201217:30:00 35 10.4 7.51 49 40 16.5 11.2 8.33 18:00:00 35 10.4 7.51 66 4316.2 AVERAGE AT HIGH FLOW 42.33 28.00 11.75 *polymer and water solution

TABLE 4 RESULTS OF DRILL MUD PROCESSING OF FIRST SECTION Mud flows,Densities Suspended polymer and Humidity Perforated Solids (TTS) andwáter of The Feet Date Time Properties of Mud And Turbidity Solids ordischarge Depth Day/Mo Hour/Min/ μ P Intermediate Final Cuts Water (ft)Year Sec cps (ppg) mgl mgl NTU P (ppg) P(ppg) 10530 14:40:00 20 10.408.5 98 54.5 10530 15:00:00 20 10.40 8.5 92 51.5 10530 15:20:00 20 10.408.5 88 42.9 10530 17 Jun. 2012 15:40:00 20 10.40 8.5 195 91.4 1053016:00:00 20 10.40 8.5 240 143.2 10530 17:00:00 20 10.40 8.5 57 31.810530 17:20:00 20 10.40 8.5 69 26.3 10530 17:40:00 20 10.40 8.5 86 38.6AVERAGES 115.63 87.75 60.03 12.5 8.33 11160 13:00:00 12 9.2 9.0 574 45811160 13:30:00 12 9.2 9.0 524 446 11160 20 Jun. 2012 14:00:00 12 9.2 9.0463 414 11160 14:30:00 12 9.2 9.0 392 300 11160 15:00:00 12 9.2 9.0 378294 11160 15:30:00 12 9.2 9.0 435 305 AVERAGES 461 369.5 8.33

TABLE 5 RESULTS OF DRILL MUD PROCESSING OF SECOND AND THIRD SECTIONCONVENTIONAL EQUIPMENT FOR INVENTION IN THE AREA SOLID CONTROL OF SOLIDCONTROL ENERGY CONSUMPTION 30% LESS THAN CONVENTIONAL EQUIPMENT SOLIDTRANSPORT USE OF TRUCK ELIMINATION OF TRUCK EQUIPMENT EQUIPMENT DIESELCONSUMPTION 27% LESS THAN CONVENTIONAL EQUIPMENT SUSPENDED SOLIDS FIRST240 UP TO 400 MG/L LESS THAN 20 MG/L SECTION SUSPENDED SOLIDS 2500 TO8000 MG/L LESS THAN 390 MG/L SECOND AND THIRD SECTION FLOWS VARIABLECONSTANT SUCTION CAPACITY CLEAN FLUID FLUIDS WITH CONTENT OF SOLIDS,SANDS, CLAY OIL ELIMINATION DOES NOT ELIMINATE ELIMINATES 98% PROCESSINGFLOW LESS THAN 450 GPM 1200 GPM MAINTENANCE HIGH COST LOW COST CAPACITYFOR LIMITED CONTINUOUS PROCESSING CONTAMINATION DUE TO 89 DB 0 DB NOISE

I claim:
 1. A dehydrator system comprising a mixing unit, a core dehydrator and a solids removal system, wherein the mixing unit comprises a rapid mixing manifold positioned and a plurality of flocculator chambers; the core dehydrator comprises a clarifying sediment chamber having a plurality of small deflector plaques and a plurality of large deflector plaques and a drag solid transition zone, each of the plurality of small deflector plaques being positioned at different heights, wherein the rapid mixing manifold is positioned in the mixing unit and is in fluidic communication with the plurality of flocculator chambers, the clarifying sediment chamber is in fluidic communication with the drag solid transition zone, the drag solid transition zone is in fluidic communication with the plurality of flocculator chambers; and the solids removal system is fluidic communication with the drag solid transition zone of the core dehydrator, the solids removal system comprises a large rotating paddle, a small rotating paddle, and a drive shaft, the drive shaft is configured to rotate the large rotating paddle and the small rotating paddle, and the large rotating paddle and the small rotating paddle are configured to move solids out of the core dehydrator.
 2. The dehydrator system of claim 1, wherein the mixing unit further comprises a plurality of stir tanks.
 3. The dehydrator system of claim 1, wherein the mixing unit further comprises a mud conditioning tank.
 4. The dehydrator system of claim 1, wherein the core dehydrator further comprises a large cylindrical section and a small cylindrical section in fluidic communication with the large cylindrical section.
 5. The dehydrator system of claim 4, wherein the large rotating paddles are positioned with the large cylindrical section.
 6. The dehydrator system of claim 4, wherein the small rotating paddle is positioned within the small cylindrical section.
 7. The dehydrator system of claim 1, further comprising a solids pump in fluidic communication with the core dehydrator.
 8. A method of removing solids from drilling fluids comprising the steps of: providing drilling fluids to a dehydrator system comprising a solids removal system in fluidic communication with a core dehydrator, wherein the core dehydrator comprises a clarifying sediment chamber comprising a plurality of small deflector plaques and a plurality of large deflector plaques, each of the plurality of small deflector plaques being positioned at different heights, the solids removal system comprises a large cylindrical section, a large rotating paddle, a small cylindrical section, a small rotating paddle and a drive shaft, the drive shaft is connected to the large rotating paddle and the small rotating paddle, and the large cylindrical section and the small cylindrical section are in fluidic communication with the plurality of small deflector plaques and the plurality of large deflector plaques; mixing drilling fluids with polymer solution in a mixing unit to produce flocculated drilling fluids comprising micro-floccules; collecting micro-floccules with the small deflector plaques and the large deflector plaques wherein micro-floccules agglutinate and enlarge producing solids; separating the solids from the flocculated drilling fluids; and removing solids from the dehydrator system, wherein the large rotating paddle and the small rotating paddle are configured to move solids from the large cylindrical section to the small cylindrical section and out of the dehydrator system.
 9. The method of claim 8, wherein the drilling fluids are rapidly mixed creating a turbulent fluid flow.
 10. The method of claim 8, wherein drilling fluids and polymer solution are mixed under turbulent fluid flow.
 11. The method of claim 8, wherein the turbulent fluid flow transitions to a laminar flow.
 12. A solids removal system for a dehydrator system, the dehydrator system having a core dehydrator and a mixing unit, the core dehydrator comprising a clarifying sediment chamber comprising a plurality of small deflector plaques in fluidic communication with a plurality of large deflector plaques, each of the plurality of small deflector plaques being positioned at different heights, and the mixing unit comprising a rapid mixing manifold in fluidic communication with a plurality of vertical flocculators, the solids removal system comprising: a large rotating paddle; a small rotating paddle; and a drive shaft, wherein the large rotating paddle and the small rotating paddle are connected to the drive shaft and in fluid communication with core dehydrator to dispose solids from the dehydrator system.
 13. The solids removal system of claim 12, wherein the large rotating paddle is positioned within a large cylindrical section of the core dehydrator.
 14. The solids removal system of claim 11, wherein the small rotating paddle is position with a small cylindrical section of the core dehydrator.
 15. The solids removal system of claim 11, further comprising a solids pump connected to the core dehydrator. 